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Controls Engineer Jobs in Madison, WI (NOW HIRING)

Milliken

Ironwood Process Controls Engineer

Portage, WI · On-site

$88K - $114K/yr

The Plant Controls Engineer works closely with maintenance, production, engineering, and other plant personnel to troubleshoot issues, optimize control systems, and implement improvements that ...

Generac

Senior Controls Engineer

Madison, WI · On-site +1

$115K - $155K/yr

The Senior Controls Engineer serves as the technical lead for advanced microgrid control system projects within the Generac Microgrid Controls Team. This role owns projects endtoend-from sales ...

American Recruiters

CONTROLS MANAGER

Madison, WI

$84K - $108K/yr

If you are a Controls Engineering Manager leading a team of software and hardware engineers of PLCs, looking for new challenges, this opportunity is for you. Our client is growing, and desires to ...

Pro Mach, Inc.

Controls Engineering Manager

Middleton, WI · On-site

$83K - $108K/yr

Quest is seeking a talented Controls Engineering Manager. You'll oversee and direct the controls engineering team for Quest that executes the design, manufacture, and implementation of automated and ...

Promachbuilt

Controls Engineering Manager

Middleton, WI · On-site

$83K - $108K/yr

Quest is seeking a talented Controls Engineering Manager. You'll oversee and direct the controls engineering team for Quest that executes the design, manufacture, and implementation of automated and ...

ProMach

Controls Engineering Manager

Middleton, WI · On-site

$83K - $108K/yr

ProMachBrands.com. Quest is seeking a talented Controls Engineering Manager. You'll oversee and direct the controls engineering team for Quest that executes the design, manufacture, and ...

Pro Mach

Controls Engineering Manager

Middleton, WI

$83K - $108K/yr

ProMachBrands.com. Quest is seeking a talented Controls Engineering Manager. You'll oversee and direct the controls engineering team for Quest that executes the design, manufacture, and ...

Realta Fusion, Inc.

Lead Fusion Controls Developer

Madison, WI · On-site

$45.50 - $58.25/hr

The Lead Fusion Controls Developer will design, build, and own parts of the control systems and software that operate Realta's suite of fusion devices, post-processing, and simulation tools. This is ...

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All JobsControls Engineer JobsControls Engineer Jobs in Madison, WI

Controls Engineer information

See Madison, WI salary details

$55.4K

$97.3K

$132K

How much do controls engineer jobs pay per year?

As of Jul 13, 2026, the average yearly pay for controls engineer in Madison, WI is $97,310.00, according to ZipRecruiter salary data. Most workers in this role earn between $84,100.00 and $108,800.00 per year, depending on experience, location, and employer.

What engineers make $300,000 a year?

Controls engineers with extensive experience, specialized skills in automation, and advanced certifications can earn salaries approaching or exceeding $300,000 annually, especially in high-demand industries or senior leadership roles. Such compensation often includes bonuses, profit sharing, or stock options, and typically requires advanced knowledge of PLCs, SCADA systems, and programming languages like Python or C++.

What Is a Controls Engineer?

Controls engineers design, develop, and test automated or dynamic systems that are controlled through feedback with sensors or detectors. Examples include automated irrigation systems that can sense moisture levels in soil, or self-driving cars that can navigate congested streets. Controls engineers apply control theory to devices, machines, and processes to attain desired outcomes. They can work on everything from boilers, washing machines, or light switches to complex industrial machinery.

What are the key skills and qualifications needed to thrive as a Controls Engineer, and why are they important?

To thrive as a Controls Engineer, you need a solid background in electrical engineering, automation, and process control, typically supported by a relevant engineering degree. Familiarity with PLC programming, SCADA systems, HMI software, and certifications such as Professional Engineer (PE) or Siemens/Rockwell training are commonly required. Strong problem-solving abilities, attention to detail, and effective communication skills help distinguish top performers in this field. These skills ensure the safe, efficient, and reliable operation of automated systems critical to industrial and manufacturing environments.

What does a Controls Engineer do?

A Controls Engineer designs, develops, and maintains systems that control machinery and processes in industries such as manufacturing, automotive, and energy. They work with automation systems, including programmable logic controllers (PLCs), sensors, actuators, and human-machine interfaces (HMIs) to ensure efficient, safe, and reliable operation. Controls Engineers also troubleshoot and optimize existing systems, implement upgrades, and ensure compliance with safety standards. Their expertise is crucial for improving productivity, reducing downtime, and integrating new technologies into production environments.

What exactly does a controls engineer do?

A controls engineer designs, develops, and maintains control systems used in manufacturing, automation, and industrial processes. They work with programmable logic controllers (PLCs), sensors, and actuators to ensure machinery operates efficiently and safely, often using engineering software and adhering to safety standards. Their role involves troubleshooting, system integration, and optimizing control processes to improve performance.

How much do control engineers get paid?

Control engineers typically earn a median annual salary between $70,000 and $100,000, depending on experience, location, and industry. Entry-level positions may start around $60,000, while experienced professionals with specialized skills or certifications can earn over $110,000. Salaries often increase with proficiency in PLC programming, automation systems, and relevant software tools.

What engineers make $200,000 a year?

Controls engineers with extensive experience, specialized skills in automation, and advanced certifications can earn salaries of $200,000 or more annually, especially in high-demand industries like manufacturing, aerospace, or energy. Senior-level engineers often have 10+ years of experience and expertise in PLC programming, robotics, and system integration.

What is the difference between Controls Engineer vs Electrical Engineer?

AspectControls EngineerElectrical Engineer
Required CredentialsBachelor's in Electrical, Mechanical, or Controls Engineering; certifications like Certified Control Systems Technician (CCST)Bachelor's in Electrical Engineering; Professional Engineer (PE) license often preferred
Work EnvironmentManufacturing plants, automation facilities, industrial settingsDesign offices, research labs, power plants, industrial sites
Industry UsageAutomation, manufacturing, process controlPower generation, electronics, telecommunications, industrial systems
Common Search/ComparisonControls Engineer vs Electrical Engineer

Controls Engineers focus on designing, developing, and maintaining control systems for automation and manufacturing processes, often working closely with machinery and PLCs. Electrical Engineers have a broader scope, working on electrical systems, power distribution, and electronic devices. While both roles require electrical knowledge and certifications, Controls Engineers specialize more in automation and control systems, whereas Electrical Engineers may work across various electrical disciplines.

What are common challenges faced by Controls Engineers when working on multidisciplinary project teams?

Controls Engineers frequently collaborate with mechanical, electrical, and software engineers, which can present challenges in aligning design standards, timelines, and communication styles. They must ensure that control systems integrate seamlessly with hardware and software components while also meeting safety and regulatory requirements. Effective communication and adaptability are essential, as Controls Engineers often act as a bridge between technical disciplines to troubleshoot issues and implement solutions efficiently.
More about Controls Engineer jobs
What are the most commonly searched types of Controls Engineer jobs in Madison, WI? The most popular types of Controls Engineer jobs in Madison, WI are:
What are popular job titles related to Controls Engineer jobs in Madison, WI? For Controls Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Controls Engineer jobs in Madison, WI look for? The top searched job categories for Controls Engineer jobs in Madison, WI are:
What cities near Madison, WI are hiring for Controls Engineer jobs? Cities near Madison, WI with the most Controls Engineer job openings:
Controls Engineer jobs near you
Infographic showing various Controls Engineer job openings in Madison, WI as of July 2026, with employment types broken down into 85% Full Time, 12% Part Time, 2% Contract, and 1% Nights. Highlights an 92% Physical, 3% Hybrid, and 5% Remote job distribution, with an average salary of $97,310 per year, or $46.8 per hour.
Ironwood Process Controls Engineer

Ironwood Process Controls Engineer

Milliken & Company

Portage, WI • On-site

$88K - $114K/yr

Full-time

Posted 25 days ago

Milliken & Company rating

7.4

Company rating: 7.4 out of 10

Based on 32 frontline employees who took The Breakroom Quiz

20th of 57 rated fashion and textile manufacturers

Job description

Milliken & Company is a global manufacturing leader whose focus on materials science delivers tomorrow's breakthroughs today. From industry-leading molecules to sustainable innovations, Milliken creates products that enhance people's lives and deliver solutions for its customers and communities. Drawing on thousands of patents and a portfolio with applications across the textile, flooring, chemical and healthcare businesses, the company harnesses a shared sense of integrity and excellence to positively impact the world for generations. Discover more about Milliken's curious minds and inspired solutions at Milliken.com and on Facebook, Instagram and LinkedIn.
POSITION TITLE
Ironwood Process Controls Engineer
POSITION OVERVIEW
The Plant Controls Engineer serves as the primary technical resource responsible for the reliability, maintenance, and continuous improvement of Encapsys' PLCs, HMIs, and power distribution systems. This role supports both daily plant operations and assigned capital or improvement projects.
Timely diagnosis and resolution of control system issues are critical, as failures in these areas can directly impact production efficiency, product quality, and customer shipments. The Plant Controls Engineer works closely with maintenance, production, engineering, and other plant personnel to troubleshoot issues, optimize control systems, and implement improvements that enhance safety, reliability, and performance.
This position is based in Portage, Wisconsin at Encapsys, a wholly owned subsidiary of Milliken. The role includes 24/7 on-call support, excluding approved vacation periods. Standard work hours are typically Monday through Friday, with flexibility and limited work-from-home opportunities when operationally feasible. The Plant Controls Engineer will support multiple sites and must be willing to travel as needed to provide on-site assistance.
JOB RESPONSIBILITIES
  • Maximize uptime and minimize interruptions to plant control systems and production equipment.
  • Improve the reliability, performance, and stability of plant PLC, HMI, and industrial systems.
  • Deliver the electrical and controls scope of projects on time and within approved budgets.
  • Travel between Portage and Appleton Encapsys sites to support, maintain, and improve all control systems.
  • Design, implement, and manage plant electrical power distribution systems, PLC control systems, and HMI applications.
  • Identify and implement projects to address control system component obsolescence and reliability improvements.
  • Manage control system service contracts to return the best value
  • Develop and recommend electrical specifications in compliance with applicable industry standards, codes, and best practices.
  • Review, approve, and release detailed electrical drawings for production, construction, and installation.
  • Assign and coordinate project work for internal and external engineers, programmers, and CAD designers, providing technical direction and oversight.
  • Communicate project status, risks, mitigation strategies, and improvement opportunities through written reports, presentations, and conference calls.
  • Manage project execution through routine status reviews and coordination with stakeholders.
  • Prepare written capital project requests that clearly define scope, schedule, resource requirements, and business justification.
  • Track project costs against approved budgets and provide regular updates to project teams and management.
  • Apply Lean and Continuous Improvement principles to identify and implement enhancements to control systems and communications that reduce cycle time, improve quality, and reliability.
  • Evaluate equipment maintenance strategies and recommend appropriate spare parts inventories to support reliable operations.
  • Participate in quarterly capital planning meetings to support long-term site investment planning.

QUALIFICATIONS - REQUIRED
  • Associate of Science degree in Electrical Engineering or a closely related technical field.
  • Minimum of one (1) years of relevant industrial electrical or controls engineering experience.
  • Ability to travel to multiple Encapsys sites up to 25% of the time.
  • Substantial hands-on experience in:
    • Allen-Bradley / Rockwell Automation PLC platforms
    • HMI development
    • Plant-level electrical power distribution systems
    • Process integration and optimization
  • Demonstrated understanding of industrial instrumentation with the ability to specify instrumentation requirements for capital projects.
  • Strong project management capabilities, including prioritization, organization, resource allocation, multitasking, and use of business or cost analytics.
  • Proficiency with Rockwell Studio 5000 and FactoryTalk software applications.
  • Working knowledge of AutoCAD, AutoCAD Electrical, and Microsoft Office tools, including Word, Excel, PowerPoint, and Microsoft Project.
  • Excellent interpersonal, verbal, and written communication skills, including the ability to deliver clear technical presentations.
  • Strong team orientation with proven ability to collaborate effectively with plant operators, engineers, and external contractors.
  • Ability to proactively identify, surface, and address conflicts or issues that may impede project or operational progress.
  • Kaizen-focused mindset with demonstrated ability to promote, lead, and sustain continuous improvement initiatives.
  • Experience interfacing with customers, senior leadership, and cross-functional stakeholders such as process and research engineers.
  • Safety: Adhere to all plant safety policies and regulatory requirements. Actively participate in safety initiatives, including audits, improvement projects, hazard identification, safety teams, and completion of all required annual safety training.
  • Quality: Demonstrate knowledge of and compliance with Milliken Quality Policy, applicable Standard Operating Procedures (SOPs), relevant ISO 9000 standards, and all company policies applicable to the role.

QUALIFICATIONS - PREFERRED
  • Bachelor of Science degree in Electrical Engineering or a closely related technical field.
  • 1-3 years of experience in electrical engineering and industrial control systems, with application in a manufacturing environment
  • Experience in chemical, pharma, and/or liquid food processing facilities
  • Familiarity with Plant Pax 5.0 and OSI PI products desired

#LI-AP1
Milliken is an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to actual or perceived race, color, creed, religion, sex or gender (including pregnancy, childbirth or related medical condition, including but not limited to lactation), sexual orientation, gender identity or gender expression (including transgender status), ancestry, national origin, citizenship, age physical or mental disability, genetic information, marital status, veteran or military status or any other characteristic protected by applicable law.
To request a reasonable accommodation to complete a job application, pre-employment testing, a job interview, or to otherwise participate in the hiring process, please contact TalentAcquisition@milliken.com.
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